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Thread: swirl flaps/manifold DIY replacement

  1. #1
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    Default swirl flaps/manifold DIY replacement

    hello,

    the flap op bar has worn on my 52k mile 55plate dth150 and the is lots axial play and whistling.

    i have looked on here and other sources as well as talking to vx mechs and i am in information overload, lots of conflicting info going about.

    as this seems the best site, can the following be confirmed (or not) before i start.

    1)the cam belt doesnt need touching/changing as you can clamp the pulley to the back plate and remove the H P pump (belt changed at 49k)
    2) there is a new design of manifold with a cranked arm (part number ??)
    3) you need to replace the flap operating solinoid as it teaches itself the flap position on the first few operations and cannot be re-taught.
    4) It won't need tech2/vauxcom-ing after to reset ecu
    5) it should take about 4 hours
    6) no special tools needed if not touching cam belt

    any help appreciated

    cheers

    Andy

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    I'm having the same trouble myself,so I would like to have those questions answered.Vauxhall have quoted £874.14 to replace the manifold and swirl motor.As I've only had the car for 6 weeks, I'm trying to get the garage where I brought it from to sort it, but they're saying my 3 month warranty covers parts only and I would have to pay the labour costs.

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    should all 06 onwards z19dth's have a modified manifold fitted as it only seems to affect 55's ????

  4. #4
    Regular Member AntSSSS's Avatar
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    Vehicle : Vectra Estate

    Trim : SRI

    Engine : CDTI 150 (Z19 DTH)

    Year : 2008

    Mileage : 100k

    Default

    Quote Originally Posted by dth150 View Post
    hello,

    the flap op bar has worn on my 52k mile 55plate dth150 and the is lots axial play and whistling.

    i have looked on here and other sources as well as talking to vx mechs and i am in information overload, lots of conflicting info going about.

    as this seems the best site, can the following be confirmed (or not) before i start.

    1)the cam belt doesnt need touching/changing as you can clamp the pulley to the back plate and remove the H P pump (belt changed at 49k)
    I had my belt changed as vx charged me no extra - just the cost of a belt, and my car had done 38k and never had a belt - so cant really answer that mate
    2) there is a new design of manifold with a cranked arm (part number ??)
    The new inlet has revised swirl flaps. Its the excessive up and down movement on the swirl flaps that wears the ball joints and also the bar and causes the bar to part on the joints etc - and also lets in gunk that causes the flaps to gunk up.
    3) you need to replace the flap operating solinoid as it teaches itself the flap position on the first few operations and cannot be re-taught.
    Yes! - the solinoid learns the movement of the specific inlet. Put an old one on a new Inlet and you will have issues with the flaps sticking again.
    4) It won't need tech2/vauxcom-ing after to reset ecu
    It will need some form of tech2/vauxcom yes. Mainly to run the swirl flap test once the new one is fitted - which I am not even sure you can do from vauxcom - I think you may need an actual tech2 - not sure tho. Also you may have to remove the odd error code that has arisen from all the removal and re-fitting.
    5) it should take about 4 hours
    Thats going some!.. I would be VERY happy with only a 4 hr labour charge for complete removal and refitting of the inlet and all ancillary items..
    6) no special tools needed if not touching cam belt
    Not 100% sure - cant think of any thing

    any help appreciated

    Hope that kind of helps
    cheers

    Andy
    See my comments in Red mate, I have had this done on my 05 plate cdti 150.

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    Vehicle : Golf 7

    Trim : GTD

    Engine : 2.0 TDI 184PS

    Year : 2014

    Mileage : 40000

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    I am having the manifold replaced today, and ithe block said its an all day shift. So I assume 7-8hrs.

    Gazza4

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    cheers for that , perhaps 4hrs was a bit hopeful, will let you know how i get on, Andy

  7. #7
    Regular Member Dan_BlackSRi's Avatar
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    Vehicle : Vectra SRi

    Trim : XP NAV

    Engine : 1.9 CDTi 150

    Year : 2007

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    Quote Originally Posted by dth150 View Post
    cheers for that , perhaps 4hrs was a bit hopeful, will let you know how i get on, Andy
    I have heard 4 hours banded about on the forum before, but for those that have actually had it done, it was more around 7 hours (mine was 7.5 hours for new inlet, actuator and cam belt kit).

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